Wire-forming apparatus

ABSTRACT

A forming device includes an input including wire in an unformed state. The forming device has a forming station configured to receive the wire, the forming station comprising a plurality of forms, each independently movable toward and away from the wire such that the forms collectively bend the wire into a formed state that is periodic and defines a wavelength. The plurality of forms bends less than a single wavelength of wire from a unformed state to a formed state at one time

CROSS-REFERENCE TO RELATED APPLICATIONS

This patent application claims priority under 35 U.S.C. §119(e) to U.S.Provisional Patent Application Ser. No. 60/940,305 entitled “WIREFORMING DEVICE AND PROCESS,” having a filing date of May 25, 2007, thecontents of which are incorporated herein by reference.

BACKGROUND

The present invention relates to a forming device and method. In oneembodiment, the forming device is configured to form a relativelystraight wire into a periodic shape, such as a sinusoidal shape. In somecases forming devices have utilized a gear or teeth to shape a generallystraight wire into a sinusoidal shape. Because there are limitations tosuch approaches, there is a need for the present invention.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates a perspective view of one embodiment of a formingdevice in accordance with one embodiment.

FIG. 2 illustrates a top view of a forming station of one embodiment ofa forming device in accordance with one embodiment.

FIG. 3 a illustrates a plurality of forms in a forming station of aforming device in accordance with one embodiment.

FIG. 3 b illustrates a segment of a wire formed in the forming stationof a forming device in accordance with one embodiment.

FIGS. 4 a-4 i illustrates a plurality of forms during a sequence offorming a wire in accordance with one embodiment.

FIGS. 5 a-5 i illustrates a plurality of forms during a sequence offorming a wire in accordance with one embodiment.

FIG. 6 illustrates a segment of a wire formed in the forming station ofa forming device in accordance with one embodiment.

FIG. 7 illustrates a perspective top view of a forming station of oneembodiment of a forming device in accordance with one embodiment.

FIG. 8 illustrates a plurality of forms in a forming station of aforming device in accordance with one embodiment.

DETAILED DESCRIPTION

In the following Detailed Description, reference is made to theaccompanying drawings, which form a part hereof, and in which is shownby way of illustration specific embodiments in which the invention maybe practiced. In this regard, directional terminology, such as “top,”“bottom,” “front,” “back,” “leading,” “trailing,” etc., is used withreference to the orientation of the Figure(s) being described. Becausecomponents of embodiments of the present invention can be positioned ina number of different orientations, the directional terminology is usedfor purposes of illustration and is in no way limiting. It is to beunderstood that other embodiments may be utilized and structural orlogical changes may be made without departing from the scope of thepresent invention. The following detailed description, therefore, is notto be taken in a limiting sense, and the scope of the present inventionis defined by the appended claims.

FIG. 1 illustrates a perspective view of forming device 10 in accordancewith one embodiment. In FIG. 1, forming device 10 includes an input 12,a forming station 14 and an output 16. In one embodiment, a spool 22holds wire 20 that is in an unformed state 20 a at input 12. Wire 20 isthen fed into forming station 14 and is formed such that it comes out ina formed state 20 b in output 16. In one embodiment, wire 20 in anunformed state 20 a is generally straight, and in a formed state 20 b isgenerally periodic. Output 16 includes a tray 50 into which wire 20 in aformed state 20 b is fed from forming station 14. An orientation axis isgiven in the figure to illustrate x, y, and z-axes.

In one embodiment, forming station 14 includes first, second, third andfourth actuated blocks 41, 42, 43 and 44. Corresponding to each actuatedblock 41-44 is first, second, third and fourth forms 31, 32, 33 and 34(illustrated in FIG. 2). In one case, each of first, second, third andfourth actuated blocks 41, 42, 43 and 44 is coupled to one of first,second, third and fourth forms 31, 32, 33 and 34 and aligned such thatthey are perpendicular to wire 20 as wire 20 moves from input 12 tooutput 16 along the x-axis. In one embodiment, first through fourthactuated blocks 41-44, and thus first through fourth forms 31-34, areactuated along the y-axis.

FIG. 2 illustrates a top view of a forming station 14 in accordance withone embodiment. First, second, third and fourth forms 31, 32, 33 and 34are respectively coupled to first, second, third and fourth actuatedblocks 41, 42, 43 and 44. In one embodiment, first, second, third andfourth actuated blocks 41, 42, 43 and 44 are seated on first, second,third and fourth rails 51, 52, 53 and 54. The x and y-axes areillustrated, and the z-axis would extend out of the page.

In FIG. 2, wire 20 is illustrated moving in the x-axis, or passing fromright-to-left as viewed in the figure, such that it is in an unformedstate 20 a entering forming station 14 on the right side and such thatit is in a formed state 20 b exiting forming station 14 on the leftside. In forming station 14, first through fourth actuated blocks 41-44and first through fourth forms 31-34 move independently and in timedsequence in the y-axis toward and away from wire 20 such that forms31-34 bend wire 20. Wire 20 exits forming station 14 in a formed state20 b, which in one embodiment, is substantially of a sinusoidal shape.

In one embodiment, first-fourth blocks 41-44 are actuated toward andaway from wire 20 along first-fourth rails 51-55, which also lie alongthe y-axis. Forming station 14 can include a variety of mechanisms thatmove blocks 41-44, and thus forms 31-34 that are coupled thereto, towardand away from wire 20 in to bend it into a formed state 20 b. Forexample, each of first-fourth blocks 41-44 on first-fourth rails 51-55can be coupled to, and actuated by, a solenoid that moves each block41-44 linearly perpendicular to wire 20. Similarly, a pneumatic devicecan be coupled to each of blocks 41-44 to actuate blocks 41-44 and forms31-34 toward and away from wire 20 as wire 20 is moved through formingstation 14. Other embodiments include other means of moving the blocks41-44 and forms 31-34 toward and away from wire 20.

FIG. 3 a illustrates a portion of first through fourth forms 31-34 of aforming station 14 in accordance with one embodiment. In one example,each of first through fourth forms 31-34 respectively include firstthrough fourth forming points 36-39. As forms 31-34 and associatedforming points 36-39 engage wire 20 as they are moved toward and awayfrom wire 20 as wire is moved through forming station 14 in thedirection indicated by arrow 25, wire 20 is bent from its unformed state20 a into its formed state 20 b.

In FIG. 3 a, each of forms 31-34 and forming points 36-39 areillustrated as extended fully “in” toward wire 20 such that a space orforming zone 35 is left between the collective group of forming points36-39. In the illustration, the width of forming zone 35 generallymatches the width of wire 20. As such, wire 20 is bent from its unformedstate 20 a by forming points 36-39 so that its formed state 20 b isgenerally similar to the shape of forming zone 35. Forming points 36-39can be configured in a variety of ways to create a variety of shapes forforming zone 35, and thus for formed state 20 b of wire 20.

In one example illustrated in FIG. 3 a, forming zone 35 has a sinusoidalshape defining an amplitude (Y₃₅) and a wavelength (λ₃₅). As wire 20 isindexed or moved through forming zone 35 in direction 25, forming points36-39 are moved toward and away from wire 20. As such, formed state 20 bof wire 20 can be a continuous sinusoidal shape.

FIG. 3 b illustrates a segment of wire 20 in a formed state 20 b that isformed in a forming station 14 in accordance with one embodiment. In theexample, wire 20 is bent from its unformed state 20 a by forming points36-39 to generally be similar to the shape of forming zone 35, such thatwire 20 in a formed state 20 b has an amplitude (Y₂₀) and has awavelength (λ₂₀). The respective amplitudes (Y₃₅ and Y₂₀) andwavelengths (λ₃₅ and λ₂₀) of forming zone 35 and wire 20 in a formedstate 20 b can be similar, but are not necessarily identical. In oneexample, wire 20 has some spring-back associated with it such that wire20 in a formed state 20 b has an amplitude (Y₂₀) that is slightlysmaller than the amplitude (Y₃₅) of forming zone 35 and has a wavelength(λ₂₀) that is slightly longer than the wavelength (λ₃₅) of forming zone35. In one example, wire 20 is a metal, such as a cobalt basedsuperalloy.

An illustration of a process of bending wire 20 from its unformed state20 a into its formed state 20 b is given in FIGS. 4-5. FIGS. 4-5illustrate first through fourth forms 31-34 and first through fourthforming points 36-39 independently and sequentially moving toward andaway from wire 20 as it moves from input 12 to output 16 through formingstation 14, thereby bending wire 20 into a formed state 20 b. FIG. 3 billustrates a portion of wire 20 into its formed state 20 b that isformed using the processes illustrated in FIGS. 4-5.

FIG. 4 illustrates an initiation of a process starting with a wire 20that is completely in an unformed state 20 a as the process begins. Inthe example, it is referred to as initial wire processing. FIG. 5illustrates subsequent processing where at least some bending of wire 20has already occurred as the process begins. In the example, it isreferred to as subsequent wire processing.

FIG. 4 a illustrates wire 20 entering first through fourth forms 31-34in forming station 14 in an unformed state 20 a, such as from input 12.Output 16 is referenced to the left in the figure. In one embodiment,this illustrates the initial wire processing for bending wire 20. InFIG. 4 a, fourth form 34 is illustrated “in” toward wire 20, while firstthrough third forms 31-33 are illustrated “out” away from wire 20. InFIG. 4 b, first form 31 is illustrated actuated in toward wire 20.Fourth form 34 remains in and second and third forms 32-33 remain out.As first form 31 is actuated in, wire 20 is moved by the impact of firstforming point 36 against wire 20.

In FIG. 4i c, second form 32 is illustrated actuated in toward wire 20.First and fourth forms 31 and 34 remain in and third form 33 remainsout. As second form 32 is actuated in, wire 20 is bent from its unformedstate 20 a by the combined impact of first and second forming points 36and 37 against wire 20. In FIG. 4 d, fourth form 34 is illustratedactuated out away from wire 20. First and second forms 31 and 32 remainin and third form 33 remains out.

In FIG. 4 e, third form 33 is illustrated actuated in toward wire 20.First and second forms 31 and 32 remain in and fourth form 34 remainsout. As third form 33 is actuated in, wire 20 is bent from its unformedstate 20 a by the combined impact of second and third forming points 37and 38 against wire 20. Because fourth form 34 remains out at that pointin time, wire 20 is allowed to move on the side of input 12. As such,only approximately one half of a single wavelength (λ₂₀) of wire 20 isbent at one time from an unformed state 20 a to a formed state 20 b. Atthat point, a single wavelength (λ₂₀) of wire 20 is constrained betweenforming points 36, 37 and 38 of first, second and third forms 31-33.

In FIG. 4 f, first form 31 is illustrated actuated out away from wire20. Second and third forms 32 and 33 remain in and fourth form 34remains out. In FIG. 4g, fourth form 34 is illustrated actuated intoward wire 20. Second and third forms 32 and 33 remain in and firstform 31 remains out. As fourth form 34 is actuated in, wire 20 is bentfrom its unformed state 20 a by the combined impact of third and fourthforming points 38 and 39 against wire 20. In this way, onlyapproximately one half of a single wavelength (λ₂₀) of wire 20 is bentat one time from an unformed state 20 a to a formed state 20 b. At thatpoint, a single wavelength (λ₂₀) of wire 20 is constrained betweenforming points 37, 38 and 39 of second, third and fourth forms 32-34.

In FIG. 4 h, second form 32 is illustrated actuated out away from wire20. Third and fourth forms 33 and 34 remain in and first form 31 remainsout. In FIG. 4 i, third form 33 is also illustrated actuated out awayfrom wire 20. First and second forms 31 and 32 remain out, while onlyfourth form 34 remains in. As such, at the end of the initial wireprocessing, since each of first, second and third forms 31, 32 and 33remain out, wire 20 is not impinged by them and can be readily moved orindexed for subsequent wire processing.

FIGS. 5 a-5 i illustrate one embodiment of such subsequent wireprocessing. As with FIG. 4 i, in FIG. 5 a only fourth form 34 isillustrated actuated in toward wire 20, while first, second and thirdforms 31, 32 and 33 remain out. Relative to wire 20 in FIG. 4 i, wire 20in FIG. 5 a is indexed slightly toward output 16. For example, viewingFIG. 4 i, a first wavelength (λ₂₀) in wire 20 (i.e., that portion ofwire 20 that transitions from “up” to “down” to “up” again, as viewed inFIG. 4i) is generally “below” forming point 37 of form 32. In FIG. 5 a,wire 20 is indexed toward output 16 by one wavelength (λ₂₀) such thatthat same wavelength (λ₂₀) is now moved past forming point 36 of form 31on the side of output 16.

In FIG. 5 b, first form 31 is illustrated actuated in toward wire 20.Fourth form 34 remains in and second and third forms 32-33 remain out.In FIG. 5c, second form 32 is illustrated actuated in toward wire 20.First and fourth forms 31 and 34 remain in and third form 33 remainsout. As first form 31 is actuated in, a previously bent portion of wire20 is secured by first and second forming points 36 and 37 against wire20. In FIG. 5 d, fourth form 34 is illustrated actuated out away fromwire 20. Third form 33 remains out and first and second forms 31 and 32remain in securing wire 20.

In FIG. 5 e, third form 33 is illustrated actuated in toward wire 20.First and second forms 31 and 32 remain in and fourth form 34 remainsout. As third form 33 is actuated in, wire 20 is bent from its unformedstate 20 a by the combined impact of second and third forming points 37and 38 against wire 20. Because fourth form 34 remains out at that pointin time, wire 20 is allowed to move on the side of input 12. As such,only approximately one half of a single wavelength (λ₂₀) of wire 20 isbent at one time from an unformed state 20 a to a formed state 20 b. Atthat point, a single wavelength (λ₂₀) of wire 20 is constrained betweenforming points 36, 37 and 38 of first, second and third forms 31-33.

In FIG. 5 f, first form 31 is illustrated actuated out away from wire20. Second and third forms 32 and 33 remain in and fourth form 34remains out. In FIG. 5 g, fourth form 34 is illustrated actuated intoward wire 20. Second and third forms 32 and 33 remain in and firstform 31 remains out. As fourth form 34 is actuated in, wire 20 is bentfrom its unformed state 20 a by the combined impact of third and fourthforming points 38 and 39 against wire 20. In this way, onlyapproximately one half of a single wavelength (λ₂₀) of wire 20 is bentat one time from an unformed state 20 a to a formed state 20 b. At thatpoint, a single wavelength (λ₂₀) of wire 20 is constrained betweenforming points 37, 38 and 39 of second, third and fourth forms 32-34.

In FIG. 5 h, second form 32 is illustrated actuated out away from wire20. Third and fourth forms 33 and 34 remain in and first form 31 remainsout. In FIG. 5 i, third form 33 is also illustrated actuated out awayfrom wire 20. First and second forms 31 and 32 remain out, while onlyfourth form 34 remains in. As such, at the end of the subsequent wireprocessing, since each of first, second and third forms 31, 32 and 33remain out, wire 20 is not impinged by them and can be readily moved orindexed for additional subsequent wire processing.

One skilled in the art will understand that the subsequent wireprocessing illustrated in FIGS. 5 a-5 i can be repeated on wire 20 inorder to create a continuous piece of formed material having asubstantially periodic, and in one example, sinusoidal-like shape, overits length. The overall length can be varied in accordance with thedesired application. Wire 20 in its formed state 20 b has sinusoidalshape with an amplitude (Y₂₀), and is generally flat along the z-axis(the dimension coming out of the page as viewed in FIGS. 2, 3 a and 3 b,for example).

As is evident from the subsequent wire processing illustrated in FIGS. 5a-5 i, when first and second forms 31 and 32 are transitioned in, theyare configured to hold or constrain wire 20 in its formed state. This isillustrated, for example, in FIG. 5 e where first and second forms 31and 32 are constraining wire 20. When third and fourth forms 33 and 34are transitioned in, they are configured to engage wire 20 in itsunformed state 20 and bend it into its formed state 20 b. This isillustrated, for example, in FIG. 5 e, where third form 33 bends wire 20from its unformed state 20 to its formed state 20 b, and in FIG. 5 g,where fourth form 34 bends wire 20 from its unformed state 20 to itsformed state 20 b. In addition, in this last example of FIG. 5 g, thirdform 33 also constrains wire 20 after it has been bent in order forfourth form 34 to accurately bend wire 20.

As is evident from the initial and subsequent wire processingillustrated in FIGS. 4-5, approximately one half of a single wavelength(λ₂₀) of wire 20 is bent at one time from an unformed state 20 a to aformed state 20 b. Put another way, when forming points 36-39 of forms31-34 are actuated to bend wire 20 from an unformed state 20 a to aformed state 20 b, less than a single wavelength (λ₂₀) of wire 20 isbent at one time. In one embodiment, when the wavelength (λ₂₀) of wire20 is significantly less than the amplitude (Y₂₀) of wire 20, bending anentire wavelength (λ₂₀) or more of wire 20 from an unformed state 20 ato a formed state 20 b at one time with forming points 36-39 can causethe formed state 20 b to be a distorted sinusoidal shape, of even causewire 20 to brake or fracture.

In one embodiment, wire 20 has a diameter of four thousandths of oneinch (0.004 inch). In other embodiments, wire 20 has a diameter as smallas one half of one thousandths of one inch (0.0005), and in others it isas large as ten thousandths of one inch (0.010 inch). Also, a singlewavelength (λ₂₀) of wire 20 created by forming points 36-39 isapproximately twenty-four thousandths of one inch (0.024 inch), whilethe amplitude (Y₂₀) of wire 20 in its formed state 20 b is andapproximately forty thousandths of one inch (0.040 inch). With thesefairly small dimensions, and with this ratio of amplitude (Y₂₀) towavelength (λ₂₀), wire 20 is fairly easily bent, and if a fullwavelength (λ₂₀) or more is bent from an unformed state 20 a to a formedstate 20 b at one time, the sinusoidal formed state 20 b illustrated inFIG. 3 a will not be achieved.

Also, where the amplitude (Y₂₀) of wire 20 in its formed state 20 b issignificantly larger than a single wavelength (λ₂₀) of formed wire 20,as illustrated in FIG. 3 b, bending a relatively small diameter into asinusoidal shape cannot effectively be achieved with a gear ortooth-type mechanism, which would effectively bend an entire wavelength(λ₂₀) of wire 20 over a tooth of the gear.

In one example, a formed wire 20 b has a sinusoidal shape where a singlewavelength (λ₂₀) of wire 20 is approximately fifty percent (50%) of theamplitude (Y₂₀), while in another example it is approximately sixtypercent (60%) and in yet another it is ninety percent (90%). The lengthof forming points 36-39 (as illustrated in FIG. 3) can be readilyadjusted to create these various proportions.

In one embodiment, each of forms first through fourth forms 31-34 areconfigured for independent actuation such that they move independentlyand consecutively in and out of a forming zone 35, for example movingalong rails 51-54. As such, the distance that forms 31-34 are actuatedtoward wire 20 can readily be adjusted during the forming process byregulating the distance of travel along rails 51-54. In this way, theamplitude (Y₂₀) of the formed state 20 b can be adjusted. In oneembodiment, the amplitude (Y₂₀) of the formed state 20 b is adjustedduring the forming process such that the overall amplitude (Y₂₀) of theformed state 20 b of wire 20 varies over its length.

Similarly, when forms 31-34 and mounting blocks 41-44 are mounted onrails in the x-axis, the wavelength (λ₂₀) of wire 20 can be adjusted.This is particularly true in the tapered region to accommodate for theslightly different wavelength produced at different amplitudes.

FIG. 6 illustrates one example of a wire 20 in a formed state 20 b thathas been formed with an amplitude (Y₂₀) that varies over its length. Forexample, near the center of the portion on wire 20 illustrated, theamplitude (Y_(20max)) is at a maximum and toward the ends of the portionthe amplitude (Y_(20min)) is at a minimum. One skilled in the art willunderstand that the amplitude can be adjusted in various ways to achievea wire in a formed state 20 b having various tapered forms.

In one embodiment, the indexing or moving a wire 20 through formingstation 14 along the x-axis is done mechanically by physically movingwire 20 by one wavelength (λ₂₀), as described and illustrated above inthe transition from FIG. 4 i to FIG. 5 a. In another embodiment, thisindexing of wire 20 can be achieved automatically with forming device10.

FIG. 7 illustrates a portion of forming station 14 for forming device 10in accordance with one embodiment. Forming station 14 includes firstthrough fourth forms 31-34, wire guide 28 and index pin 29. Wire guide28 includes slot 28 a. In the illustration, wire 20 in an unformed state20 a enters forms first through fourth forms 31-34 and exits in a formedstate 20 b.

In operation, wire 20 is bent from its unformed state 20 a to its formedstate 20 b with first through fourth forms 31-34 in accordance with theprocess described relative to FIGS. 4 a-4 i and/or 5 a-5 i. In oneembodiment, forming station 14 is configured with a wire guide 28, whichin one example is configured to direct wire 20 in its formed state 20 btoward guide pin 29. In one example, wire guide 28 is configured withslot 28 a, into which wire 20 moves in its formed state 20 b. In FIG. 7,a portion of wire 20 that has entered slot 28 a and is inside guide 28is illustrated in dotted lines.

Guide pin 29 is configured to be actuated along the z-axis, or in andout of the page as presented in FIG. 7. In one example, guide 28 isconfigured with a cylindrical bore that receives guide pin 29 so thatguide pin 29 can be actuated up or away from guide slot 28 a so thatwire 20 in its formed state 20 b can travel under guide pin 29 withinslot 28 a. Then, guide pin can be actuated down or toward guide slot 28a so that wire 20 in its formed state 20 b can be pinned within guideslot 28 a by guide pin 29, thereby holding wire 20 in place.

In one embodiment, guide 28 and guide pin 29 are moveable along thex-axis relative to first through forms 31-34. As such, guide 28 andguide pin 29 can be used to index wire 20 relative to first throughfourth forms 31-34. In one example, guide 28 and guide pin 29 are in a“back” position toward output 16 along the x-axis. Guide pin 29 isinitially “up” (along the z-axis) and away from guide slot 28 a suchthat wire 20 can move freely in slot 28 a. Then, guide pin 29 isactuated “down” (along the z-axis) to hold the wire in place.

Next, wire 20 is formed in accordance with the process described inFIGS. 4 a-4 i and/or 5 a-5 i. Then, with at least two of first throughfourth forms 31-34 still in toward wire 20 (along the y-axis), therebyholding it in place, guide pin 29 is actuated “up”. Then, guide 28 andguide pin 29 are moved to a “forward” position toward input 12 along thex-axis. Then, guide pin 29 moves downward (along the z-axis) to clamp orhold wire 20 within guide slot 28 a.

Next, all of first through forms 31-34 move out away from wire 20 (alongthe y-axis). Guide 28 and guide pin 29 are then moved back toward output16 approximately one wavelength along the x-axis. First and second forms31-32 then move in toward wire 20 (along the y-axis) and hold wire 20,then third and forth forms 33-34 actuate to bend another portion of wire20. This process can then be repeated to continually index and bend wire20.

In one embodiment, one or more of first through forth forms 31-34 can bemovable along the x-axis in addition to along the y-axis. In this way,the forms themselves can be used to index wire 20. For example, railssimilar to rails 51-54 in FIG. 2 could extend along the x-axis and allowfirst through forth forms 31-34 to be actuated in that direction aswell.

In one example, guide 28 is stationary in all x-, y- and z-axis axes,and guide pin 29 is stationary in the x- and y-axes, while moving in thez-axis. Guide pin 29 starts out in the “down” position. Wire 20 isformed in accordance with the process described in FIGS. 4 a-4 i and/or5 a-5 i. Then, first and second forms 31 and 32 are transitioned intoward wire 20 (along the y-axis), while third and forth forms 33 and 34are transitioned out away from wire 20 (along the y-axis). Guide pin 29is then actuated “up” (along the z-axis).

Next, first and second forms 31 and 32 are then moved back toward output16 approximately one wavelength along the x-axis. Guide pin 29 thenmoves downward (along the z-axis) to clamp or hold wire 20 against guide28 within guide slot 28 a. Next, first and second forms 31 and 32 aretransitioned out away wire 20 (along the y-axis). Then, first and secondforms 31 and 32 are moved to forward toward input 12 approximately onewavelength along the x-axis (back to the position from which they came).

Then, first and first and second 31 and 32 are transitioned in towardwire 20 along the y-axis to hold the part. Then, third and fourth forms33 and 34 can continue to bend wire 20 in accordance with the processdescribed in FIGS. 4 a-4 i and/or 5 a-5 i. Guide pin 29 is thenretracted from guide slot 28 a, and this process can then be repeated tocontinually index and bend wire 20.

One skilled in the art understands that various embodiments are possibleto accomplish the indexing of wire 20. This can be done automatically,or even manually with an operator moving the wire after each sequencedetailed in FIGS. 5 a-5 i by one wavelength and visualizing each indexone at a time.

One skilled in the art also understands that various periodic shapes maybe achieved for the formed state 20 b of wire 20. FIG. 8 illustrates aportion of first through fourth forms 71-74 of a forming station 14 inaccordance with one embodiment. In FIG. 8, each of forms 71-74 and areillustrated as extended fully “in” toward wire 20 such that a space orforming zone 75 is left between the collective group of forms 71-74.

In one example, each of first through fourth forms 71-74 respectivelyinclude forming points. In this example, the forming points furtherinclude features or grooves that give a forming zone 75 a modifiedsinusoidal shape. Although wire 20 bent in forming zone 75 will have aperiodic shape, it will not be a true sinusoidal shape. Forming zone 75has a modified sinusoidal shape defining an amplitude (Y₇₅) and awavelength (λ₇₅). One skilled in the art will understand that variousshape for forming zones are achievable with modification to the forms.For example, the forms can include other features, or may even beslanted slightly to produce “tilted” sinusoidal formed wires.

Although specific embodiments have been illustrated and describedherein, it will be appreciated by those of ordinary skill in the artthat a variety of alternate and/or equivalent implementations may besubstituted for the specific embodiments shown and described withoutdeparting from the scope of the present invention. This application isintended to cover any adaptations or variations of the specificembodiments discussed herein. Therefore, it is intended that thisinvention be limited only by the claims and the equivalents thereof

1. A forming device comprising: an input including wire in an unformedstate; and a forming station configured to receive the wire from theinput, the forming station comprising a plurality of forms, eachindependently movable toward and away from the wire such that movementof the forms toward the wire bend the wire into a formed state that isperiodic and defines a wavelength; wherein the plurality of forms bendless than a single wavelength of wire from a unformed state to a formedstate at one time.
 2. The forming device of claim 1, wherein theplurality of forms bend substantially one half of a single wavelength ofwire from an unformed state to a formed state at one time.
 3. Theforming device of claim 1, wherein the plurality of forms constrains nomore than one and one half wavelength at one time.
 4. The forming deviceof claim 1, wherein the plurality of forms bend no more than a singlewavelength of wire at one time.
 5. The forming device of claim 1,wherein the formed state is a sinusoidal shape having an amplitude and awavelength, the amplitude being greater than the wavelength.
 6. Theforming device of claim 5, wherein the wavelength is 40-90 percent ofthe amplitude.
 7. The forming device of claim 5, wherein the amplitudeis between twenty five thousandths of an inch and forty thousandths ofan inch and the wavelength is between fifteen thousandths of an inch andtwenty four thousandths of an inch.
 8. The forming device of claim 1,wherein the diameter of the wire is between one half of one and tenthousandths of one inch.
 9. The forming device of claim 1 furthercomprising: a guide configured to receive the wire in its formed state;a clamping mechanism configured to actuate such that the wire is pinnedagainst the clamping mechanism when the clamping mechanism is actuatedin toward the guide.
 10. A forming device comprising: an input includingwire in an unformed state; and a forming station configured to receivethe wire from the input, the forming station comprising a plurality offorms, each having respective forming points defining a forming zoneconfigured to bend the wire into a formed state of periodic shape havinga wavelength; wherein the forming zone bends no more than one half ofthe wavelength of wire from a unformed state to a formed state at onetime.
 11. The forming device of claim 10, wherein the formed state is asinusoidal shape having an amplitude and a wavelength, the amplitudebeing greater than the wavelength.
 12. The forming device of claim 10further comprising: a guide configured to receive the wire in its formedstate; a clamping mechanism configured to actuate such that the wire ispinned against the clamping mechanism when the clamping mechanism isactuated in toward the guide.
 13. The forming device of claim 12,wherein the guide, clamping mechanism and the forms cooperated to movethe wire toward the output by one wavelength.
 14. A forming devicecomprising: an input including a wire in an unformed state; a formingstation configured to receive the wire from the input and to bend thewire into a formed state of periodic shape having a wavelength; anoutput configured to receive the wire in the formed state; first andsecond output forms in the forming station and adjacent the output, thefirst and second output forms configured to actuate toward the wire inorder to hold the wire in its formed state; and first and second inputforms in the forming station and adjacent the input, the first andsecond input forms configured to actuate toward the wire in its unformedstate in order to bend the wire to its formed state.
 15. The formingdevice of claim 14, wherein the first input form is further configuredto both hold and to form wire.
 16. The forming device of claim 14,wherein the formed state is a sinusoidal shape having an amplitude and awavelength, the amplitude being greater than the wavelength.
 17. Theforming device of claim 16, wherein the first and second input formsbend less than a single wavelength of wire from a unformed state to aformed state at one time.
 18. The forming device of claim 16, whereinthe forming station forms the wire during initial wire processing andsubsequent wire processing and wherein the first and second output formsonly hold the wire in its formed state and do not bend the wire from itsunformed state to its formed state during subsequent wire processing.19. A method of forming a wire into a formed state of periodic shapehaving a wavelength, the method comprising: receiving the wire in anunformed state actuating first and second output forms adjacent theoutput toward the wire in order to hold the wire; actuating first andsecond input forms adjacent the input toward the wire in its unformedstate in order to bend the wire to its formed state; and bending thewire less than a single wavelength at one time from a unformed state toa formed state with the first and second input forms.
 20. The method ofclaim 19 further comprising indexing the wire by one wavelength afterbending a single wavelength.
 21. The method of claim 19 furthercomprising actuating first input form toward the wire in order to bend,and subsequently to hold the formed wire in order for the second inputform to accurately bend the wire.